Mailer, method and device for automatically inserting media therein

ABSTRACT

A dual pocket envelope capable of receiving multiple inserts, including optical media. A method of insertion and related equipment for introducing inserts and media therein. The envelope is formed from a single sheet, customizable in size and shape. The single sheet is folded and fastened to create the dual pocket envelope. Optical media and other inserts are placed in the envelope in a step-wise manner, using a novel insertion equipment.

BACKGROUND

[0001] The direct mail industry has historically utilized envelopes withsingle pockets for automated insertion of mailing components. In thepast, mailing components historically have only included paper or likematerials. To maximize efficiency, the direct mail industry has utilizedautomated machine-based processes for preparing mailings, includinginserting materials, sealing, and addressing the envelopes and applyingpostage. However, with the rapid growth of Internet usage and personalcomputing at the household level, there is a growing necessity to mailoutnumbers of electronic and optical media discs and devices to beincluded in direct mailers. Most of the computers being used byconsumers at the household level, whether PC or Macintosh, are installedwith optical media disc drives, which can read from and wrote ontoremovable media discs of various formats. These formats include theubiquitous CD-ROM format, as well as the increasingly utilized CD-R,CD-RW, DVD-ROM, DVD-R, DVD-RW, DVD+RW formats, as well as compact discsof other removable media types. Currently there is a growing need feltby the direct mail industry for a means to prepare and deliver, in acost effective automated insertion manner removable media and/or plasticmedia included with paper inserts or like materials through the mail toconsumers. This is being driven by the growing awareness among DirectMail marketers of the advantages of mailed removable media discs assales and marketing vehicles. These advantages stem mainly from 1) thelarge capacity of such discs, such as CDROM and DVDROM discs, and 2)their ability to function dynamically as two-way communication devices.A description of these advantages is in order.

[0002] The digital capacity of a standard 12 cm CDROM disc, for example,is close to 700 megabytes. With this capacity, a marketer can advertisea product with over 60 minutes of video and thousands of pages ofhigh-quality graphics and text. In other words, a marketer could placean entire catalogue on such a disc, use only the highest qualitygraphics, and support each product and/or service with video vignettes.The capacity would be even larger for a DVDROM disc. For the samemarketer to mail the equivalent content without the benefit of such adisc, one or more bulky VHS tapes would be required, along with one ormore thick and fairly heavy catalogues. All combined, the mailer withoutthe disc would likely be impractically large and would incur asignificantly higher postage rate.

[0003] The other main advantage of removable media discs is theirability to dynamically capture data. The same CDROM disc described abovewould be able to connect to the Internet via an Internet connection onthe computer in which it is played. The marketer could thereforegenerate e-commerce sales and collect valuable marketing data from theconsumer without the need and costs associated therewith for 1-800number support or pre-printed reply/mail-in cards.

[0004] With the above advantages considered, the reader may presumethere has been an explosion of Direct Mail that incorporates removablemedia. This has not, however, been the case. The reason for this is therelative newness of the removable media as sales and marketing devices,to which the Direct Mail industry has not yet reacted.

[0005] There is also a need in the Direct Mail industry for additionalprintable “real estate” or surfaces of envelopes to enhance the abilityof advertisers to get their message across. Advertisers for years haveused traditional printed paper media in their direct mail advertisingcampaigns. Advertisers have balked, however, at utilizing optical mediasolely in their advertising campaigns because of the perception that ifthe recipient does not place the optical media in their computer, theadvertiser's message has not been delivered. Advertisers perceive aneed, therefor, to combine printed paper media with optical media intheir advertising campaigns so as to assure their advertiser's messageis delivered.

[0006] Current service providers and original equipment manufacturers inthe direct mail industry offer few, if any, options for direct mailersto keep up with technological advances by incorporating removable media,such as optical media discs. The direct mailing processes includeinserting of objects into envelopes, ink jet printing on the envelopes,sealing the envelopes, and applying postage. These traditionalactivities do not accommodate removable media discs, using direct mailequipment. The processes do not support the use of removable media discsin the same automated manner. For example, the current insertionmachines that automate the direct mailing processes, such as thatdescribed and disclosed in U.S. Pat. No. 4,955,185 (hereinafter the '185patent), are not designed for removable media disc insertion intoenvelopes typically used in direct mail. The result is that serviceproviders in the direct mail industry have to employ manual labor, suchas hand insertion, in order to fulfill customer requests for mailersthat incorporate removable media such as optical media discs. Moreover,the typical mailers and envelopes themselves, such as the #10 regular,#10 window, #9, 6×9 window, 6×9 regular, 9×12 catalog, 9×12 booklet, andothers, unless otherwise custom ordered, are not of a paper weight toprevent the mailer from bending around the edges of the housed disc.These sizes also do not offer a pocket in which media can beautomatically placed and in which the disc is protected from breaking,scratching or cracking. The heavier paper stocks, additional materials,and required hand labor for Direct Mail campaigns that incorporateremovable media discs, together translate into pronounced higher costs.

[0007] There does exist holders in which optical media and print mediais hand inserted. Such holders are used in the photo developing industryto provide prints to customers along with an optical disc on which isstored the customer's pictures. These holders are not suited for directmail purposes because they are not compatible with present automaticpaper insertion equipment, nor does equipment exist to accomplish theautomatic insertion of the desired optical media into a direct mailenvelope along with other marketing media. Additionally, these holders,because they position the optical disc at the edge of the holder, do notprotect the optical disc sufficiently to assure their safe processingand delivery by the postal service.

[0008] Presently, it is possible in the optical media market to insertindustry standard 12 cm and 8 cm discs by machine. However, themachinery used in this industry, such as that disclosed and described inU.S. Pat. No. 5,875,614 (hereinafter referred to as the '614 patent),only support the automated insertion of industry standard discs into alimited number of sleeve sizes. The vast majority of these sleeve sizesare of the 5 in.×5 in. variety such as the 5¼ in.×5 in., 5⅝in.×5{fraction (1/32)} in., 5¼ in.×5¼ in., 5¼ in.×5{fraction (5/16)} in.size and others. These sleeves function as a protective carrier foroptical media discs, and are not typically used as direct mail mailers.These sleeves do not provide sufficient “real estate” to get anadvertiser's message across, nor do these sleeves provide theopportunity for sending marketing media, in a automated, single-passmanner. Such sleeves are constructed from stock which is too flimsy toprotect discs from the hazards of mailing through the postal service.Furthermore, because sleeves are invariably manufactured in the twosizes mentioned above, marketers are given few options for size andconfiguration for direct mail campaigns that incorporate removable mediadiscs. Further complications arise in that these sleeves, when used asmailers or envelopes, are not automation compatible with current postalservice requirements, and must be processed in a manner that requireshigher postage charges than conventional mailers.

[0009] The existing machinery and inline single-pass machine processesused in the direct mail industry do not currently support removablemedia discs. Conversely, the existing machinery and machine processesused in the optical media industry currently do not support themultitude of different envelope sizes and configurations used in thedirect mail industry nor can they include paper inserts to accompany themedia. Therefore, mailings that incorporate removable media inserts,such as optical discs, typically incur a much higher cost than thosemailings that do not incorporate removable media inserts.

[0010] For these reasons, there is a need for a mailer that canaccommodate the direct mailing of different types of media, processed ina single-pass automated manner and sent together in one mailer, i.e.removable media, and plastic media, and paper or like materials. Thereis also a need for direct mailing equipment and processes which providefor the automated single-pass insertion of different types of mediatogether in one mailer, i.e. removable media, discs, plastic media, andpaper or like materials.

[0011] All publications, including patent documents, referred to in thisapplication are incorporated by reference in their entirety for allpurposes. All headings are provided for the convenience of the readerand should not be used to limit the meaning of the text that follows theheading, unless so specified.

SUMMARY

[0012] The present invention relates to a multiple pocket envelope, andto related methods and equipment for automatic insertion of mediatherein that satisfies the aforementioned needs. More specifically, theenvelope has two pockets that are adjacent, separated by a common wall.The pockets are arranged in a manner so that the rear wall of the outerpocket is the front wall of the inner pocket. The entire envelope isformed from a unitary blank, that can be pre-printed and converted incustomizable design and size configurations well known in the envelopeconverting field. This envelope provides extra printable “real estate”on the walls of the two pockets. The envelope is formed by folding,fastening, and optionally sealing the sides of the unitary blank.

[0013] The rear panel of the envelope is generally rectangular and hasfour sides that are defined by fold lines for four other integrallyconnected panels of the envelope which are defined as the two opposingside panels, the top panel and the bottom panel. The rear panel has bothan inside and an outside surface as defined by the final configurationof the envelope. There are two opposed side panels that are integrallyconnected or joined to the rear panel, along the fold lines, and whichare folded over to form an inner pocket leaving a portion of the rearpanel inside surface uncovered or exposed and the edges or “buckles” ofthe opposed side panels “kiss” or touch each other. Optionally, the sidepanels overlap and are connected together at one or more glueable areaslocated on the buckles or on the panels. The inner pocket so formed hasits mouth near the upper edge of the inside rear panel. The bottom panelis folded over and connected to the two opposed side panels at twoglueable areas located on the lower panel to form an outer pocketsuitable for insertion of removable media or other inserts. The bottompanel partially covers the folded opposed side panels and forms an outerpocket suitable for the insertion of removable media or other inserts.This outer pocket similarly has a mouth that is near the upper edge ofthe inside of the rear panel. The top panel is folded over the inner andouter pockets and acts to seal the inner and outer pockets. The toppanel partially covers the bottom panel upon folding. Similarly, flapsof the inner pocket can be connected to the inside of the rear panel toform an inner pocket suitable for insertion of removable media or otherinserts. Removable discs can, thus, optionally be inserted into theinner pocket and the printed inserts inserted into the outer pocket.Windows can optionally be included in either or both the bottom and rearpanels to expose additional “real estate” on the inserted media to showthrough on the face of the envelope.

[0014] The method relates to a means of inserting media inside of anenvelope, in an inline, single-pass, automated process. Morespecifically, the method includes a means for feeding an envelope, ameans for feeding media to be inserted into the envelope, and insertingthe media into the envelope.

[0015] The related equipment comprises a means for moving an envelope onor through the equipment. Furthermore, the equipment includes a meansfor feeding an envelope with one or more pockets onto the moving means.The equipment also includes a means for conveying the media, and forfeeding the media towards the envelope on the moving means. Theequipment also provides a means for inserting the media inside theenvelope pocket or pockets. Finally the equipment provides a means forconnecting with and between the moving means, the envelope and mediafeeding means, the conveying means, and the inserting means so that theequipment operates in a coordinated fashion.

[0016] The principal objects of the present invention are: to provide adual pocket envelope; to provide a dual pocket envelope with additionalprintable “real estate”; to provide such an envelope which is adaptedfor use with automatic mail insertion equipment; to provide a method ofinsertion with such automatic mail insertion equipment; to provideautomatic mail insertion equipment to accomplish automatic insertion ofmedia into envelopes, to provide such an envelope which is well adaptedfor use with automatic mail processing equipment; to provide such anenvelope that is adapted for in line, single-pass automated insertionwith a plurality of media inserts; and to provide such an envelope thatis particularly well adapted for use with optical and other removablemedia inserts. Other objects and advantages of this invention willbecome apparent from the following description taken in conjunction withthe accompanying drawings wherein are set forth, by way of illustrationand example, embodiments of this invention.

[0017] The drawings constitute apart of this specification and includeexemplary embodiments of the present invention and illustrate variousobjects and features thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018]FIG. 1 is a plan view of the envelope.

[0019]FIG. 2 is a cross-sectional view of the envelope

[0020]FIG. 3 is a view of the inside of the envelope blank

[0021]FIG. 4 is a view of the outside of the envelope blank

[0022]FIG. 5 is a view of the multiple station automated insertiondevice for media

[0023]FIG. 6 is a sectional view of the removable media insertion device

DETAILED DESCRIPTION

[0024] Definitions

[0025] “Connecting” means a method for fastening, including but notlimited to the use of booger glue, rewettable glue, or glue strip.

[0026] “Envelope” refers to an envelope already containing insertedmedia or, alternatively, an envelope devoid 6 of any inserted media.

[0027] “Media” means a type of material that can be inserted into and isotherwise removable from an envelope, including removable media definedherein, whether the material is (1) traditional paper or like materialsor (2) electronic media, or optical media discs, or othercomputer-readable object, or equivalent; (3) plastic media such ascredit cards, identification cards or related cards.

[0028] “Perforated” refers to any structurally weakened area or line.The weakening of this area or line can be accomplished by scoring,punching, folding, embossing or other like method.

[0029] “Unitary blank” means a single completely intact cut sheet ofpaper that is converted into an envelope.

[0030] “Business reply card” means a paper unit that can be removed fromthe envelope along a perforated line and separately filled out andmailed to a pre-printed address, or a coupon with pre-printedinformation, or other such equivalent.

[0031] “Removable media” means any type of electronic media such asoptical discs, magnetic discs, magneto-optical discs, solid-state memorydiscs, discs of other formats, memory cards, memory sticks, or any othercomputer-readable storage object.

[0032] “Optical media” means discs removable discs of the variousoptical media formats, such as, but not limited to, CD-ROM, CD-R, CD-RW,CD-Video, DVD-Video, DVD-ROM, DVD-RAM, DVD-R DVD-RW, DVD+RW, DVD-R/CD-RWcombo, DVD-RW/CD-RW combo, or other like equivalent.

[0033] “Suction cup” means a vacuum-operated pickup head which generatesa suction force at its surface area that is calibrated to firmly pick upor move media, envelopes, or envelope panels. The suction cup is enabledby a motorized air compressor.

[0034] As required, detailed embodiments of the present invention aredisclosed herein; however, it is to be understood that the disclosedembodiments are merely exemplary of the invention, which may be embodiedin varying forms. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as abasis for the claims as a representative basis for teaching one skilledin the art to variously employ the present invention in virtually anyappropriately detailed structure.

[0035]FIG. 3 illustrates a one-piece unitary envelope blank prior toassembly into a dual pocket envelope as shown in FIGS. 1 and 2. Withreference to FIG. 1, the envelope is constructed by well known methodsof cutting from a larger unitary piece of stock and various lines ofweakness which facilitate folding along the lines are formed on theenvelope blank by conventional and well known methods. The stock for theblank can be composed of varying materials such as those commonly usedfor direct mailing envelopes, including but not limited to paper,cardboard, plastic, glycine, polymers, and combinations of saidmaterials. The stock can be blank, to be printed upon later. The stockcan also be pre-printed, with text, figures, diagrams, drawings, andother pertinent information printed in a variety of manners toaccommodate varying methods of folding, angles, and viewing.

[0036] With reference to FIG. 3, the envelope includes a rear panel 2that is generally rectangular in shape. The four sides of rear panel 2are defined by four lines of weakness that facilitate folding orbending. The lines of weakness are represented by lines 16, 31, 46, and64.

[0037] The side panels 15 and 30 designate the right and left sidepanels respectively, and are connected to the rear panel at lines ofweakness 16 and 31 respectively which facilitate folding or bending. Theside panels 15 and 30 are folded or bent inward over the inside surfaceof rear panel 2 to create an inner pocket. The mouth of the inner pocketis formed by the upper edges 19 and 34 of side panels 15 and 30respectively. The side panels 15 and 30 can be of a size and shape as tocover the inside surface of rear panel 2 either partially or completely.Side panels 15 and 30 can be alternatively be fastened or connectedtogether, utilizing a variety of methods including remoistened glue orbooger glue, along overlapping right buckle area 20 and left buckle area21. A variety of fastening methods allow for the side panels 15 and 30to form a customizable inner pocket. The inside surfaces of side flaps15 and 30 allow for increased printable areas, maximizing the amount ofprinted information that is contained therein.

[0038] Alternatively the side panels 15 and 30 can be of such as sizeand shape as to substantially cover said rear panel 2 inside surface andto have their free side edges of the right and left side panels 17, 18and 32, 33 touching so that no portion of the inside surface of the rearpanel is exposed there between. Alternatively either or both side panels15 and 30 can comprise a perforated line, wherein a portion of all ofsaid side panels 15 and 30 can be detached at said perforated line andthe detached portion can be used as a return postcard, a business replycard or equivalent. The side panels 15 and 30 can alternatively be ofsuch a size and shape as to totally cover said rear panel 2 and to havetheir side edges 17, 18 and 32, 33 touching so that no portion of theinside surface of the rear panel is exposed there between.

[0039] Bottom panel 45 is connected to rear panel 2 at line of weakness46 that facilitates folding or bending. Bottom panel 45 is bent orfolded upwards over the inner pocket formed by side panels 15 and 30.The outer pocket has a mouth at the lower edge 47 of the bottom panel45. Bottom panel 45 can be fastened or connected to a combination ofside panel edges 17, 18, 19, 32, 33, and/or 34 utilizing a plurality ofmethods including remoistened glue or booger glue, along the right andleft edges respectively of edges 48 and 49 thus forming an outer pocket.The bottom panel 45 can alternatively be fastened or connected atglueable areas 51 and 52 to the outer surface of the right panel 15 andthe left panel 30 thus forming an outer pocket. Bottom panel 45 can beof a shape and size to partially cover the wall of the inner pocket,formed by side panels 15 and 30. Alternatively, the bottom panel 45 canbe of such size and shape as to totally cover said opposed side panels15 and 30. An optional recess 53 substantially semicircular in shapefacilitates insertion and removal of materials contained within thepockets.

[0040] Top panel 65 is connected to rear panel 2 at line of weakness 64that facilitates folding or bending. Top panel 65 is bent or foldeddownwards over the mouths of the inner and outer pockets, and provides ameans for sealing said pockets. Top panel 65 is of a shape and size topartially or fully cover bottom flap 45. Top panel 65 can be fastened orconnected to the lower edge 47 of bottom panel 45 utilizing a pluralityof methods, including remoistened glue or booger glue, at glueable area69. The top panel can be opened to expose the mouths of the containedinner and outer pockets. Alternatively, the top panel 65 can be of suchas size and shape as to totally cover said bottom panel 45.

[0041] The outer pocket can be sealed, or fastened in a manner as toallow a person to unseal or unfasten the envelope, exposing thematerials therein, and allow a person to view the inside of bottom panel45. This inside surface of bottom panel 45 and outer surface of theinner pocket present additional printable areas and thus maximize theamount of printed information that is contained therein especially whenthe glue used is translucent or clear.

[0042] The envelope can additionally have an optional window as shown inFIG. 4 on bottom flap 45 to reveal the contents of the outer pocket.This window can remain open and unsealed, or can have an 6 optionaltranslucent or transparent covering to protect the contents of the outerpocket. Such translucent or transparent coverings are well known in theart and can include various polymers or plastic sheets.

[0043]FIG. 5 illustrates one possible embodiment of the method ofinsertion and the equipment necessary to accomplish such insertion. Withregards to FIG. 5, the multiple station insertion device 3 disclosedtherein can be constructed using well known methods in the insertermanufacturing industry such as described and disclosed in the '185patent. The multiple insertion device 3 can comprise an envelope feedingstation 4; a first media insertion station 5; a second media insertionstation 6; and an envelope sealing/receiving station 7. FIG. 6 indicatesone possible embodiment of the second media insertion station 6 that canbe incorporated into existing inserters, or utilized separately. Theembodiment disclosed in FIG. 5 can comprise the envelope feeding station4, first media or envelope insertion station 5 and envelope 16 sealingstation 7 as described and disclosed in the '185 patent. Furthermore,the second media insertion station 6 as shown in FIG. 5 can represent anoptical media insertion station as disclosed in the '614 patent. Withreference to FIG. 5, the envelope is fed into envelope insertion station4 along an envelope moving means 8. One embodiment of the moving meansis the insert track structure which is described and disclosed in the'185 patent. Another embodiment of the moving means is comprised of theenvelope moving track 145 a shown in FIG. 6. The moving means guides theenvelope along movement path 180. The first media insertion station 5includes a supply of media (not illustrated) for insertion into theinner pocket of the envelope. The insertion of the media occurs asdescribed and disclosed in the '614 patent.

[0044] The second media insertion station 6 includes a media supply, oneembodiment which is the disc supply as described and disclosed in the'614 patent. Another embodiment of the media supply is illustrated inFIGS. 5 and 6 which indicates a media supply 70, comprised of aplurality of media 75, which provides media 75.

[0045] The second media insertion station 6 includes a media transferassembly 9, one embodiment which is the disc transfer assembly which isdescribed and disclosed in the '614 patent. Another embodiment of themedia transfer assembly 9 is depicted in FIG. 6. With reference to FIG.6, the media transfer assembly is supported in a cantilever fashion byvertical support 95, and is comprised of a conveying arm 85, an optionalrotatable hinge 195, to which is rotatably mounted the conveying arm 85to the vertical support 95. One end of conveying arm 85 has at least onesuction cup 80 through which vacuum is selectively applied. The suctioncup 80 can be vertically and horizontally movable with respect to theconveying arm 85. The suction cup 80 communicates with a source ofvacuum (not illustrated) through the conveying arm 85 and vacuum hose90, which is controlled by an unillustrated controller. The conveyingarm 85 is rotatable through at least 90 degrees by a pneumaticpiston-driven or equivalent rotary actuator (not illustrated) whichserves to rotate the suction cup 80 into a position substantiallyvertically aligned with the media 75 from the media supply 70. In oneoptional embodiment, an unillustrated printing mechanism prints anaddress or like data on media 75 prior to transfer by the media transferassembly 9. With vacuum applied to the suction cup 80, the conveying arm85 is then raised to remove the topmost media 75 from the media supply70, and then the conveying arm 85 is rotated at the rotatable hinge 195through about 90 degrees of arc to position media 75 above media rest250 of feeding chute 200. The conveying arm 85 is optionally lowered tobring the media 75 into engagement with feeding chute 200. Vacuum isreleased to cause suction cup 80 to release the media 75 onto the mediarest 250. The media transfer assembly 9 is optionally controlled by anunillustrated controller.

[0046] The feeding chute 200 of second media insertion station 6 is nowdescribed. The feeding chute 200 functions to take media deposited ontomedia rest 250 by the media transfer assembly 9 and move that media intoposition for insertion into the envelope. Feeding chute 200 is formed bybase 120, whose width is greater than the diameter of media 75. Base 120may optionally be comprised of such materials as to facilitate the flowof media along path 210 and to minimize damage such as scratches tomedia 75. Such materials can include polymers, felt, wood, and similarrelatively soft materials. Base 120 may optionally be comprised of anunillustrated air suspension system, which is attached to anunillustrated air pump system. The unillustrated air suspension systemcreates an unillustrated air cushion through a plurality of vents 130,which facilitates movement of media 75 along path 210, furtherprotecting the media 75 from damage. Feeding chute 200 is defined on oneend by edge 220, and an optionally recessed groove 215 to facilitatecontact between feeding piston 100 and media 75. Lip 135 defines the endof feeding chute 200, which lip is positioned to optimally allowinsertion of media 75 into an envelope. Feeding chute 200 is furtherdefined by a first and second guide wall 110 and 115 respectively, whichfurther aid in directing media 75 along path 210. Guide walls 110 and115 of feeding chute 200 may optionally be adjusted to accommodatevarying sizes of media. Feeding chute 200 may optionally be adjustedvertically to accommodate varying dimensions, thickness, and compositionof envelopes.

[0047] The pusher assembly 10 of second media insertion station 6 is nowdescribed. One embodiment of the pusher assembly is the pusher assemblyas described and disclosed in the '614 patent. Another embodiment of thepusher assembly is the pusher finger assembly as described and disclosedin the '185 patent. Another embodiment of the pusher assembly isdepicted in FIG. 6. Feeding piston 100, with optional sensor 105, isactivated by pneumatic pusher 205, which pushes media 75 along path 210.The pusher assembly is timed and coordinated in a manner as to insertmedia into an open outer pocket of an envelope positioned at the lip 135of the feeding chute 200. Feeding piston 100, the optional sensor 105,and the pneumatic pusher 205, are controlled by an unillustratedcontroller.

[0048] The moving means positions an envelope at lip 135 prior toreceiving media 75. The lip 135 contacts the upper edge 19 of the rightside panel 15 and/or the upper edge 34 of the left side panel 30. Thelip 35 thus acts to hold down the panels so that the envelope openingmechanism 11 can open only the outer pocket and not the inner pocket.The envelope opening mechanism 11 of second media insertion station 6 isnow described. One embodiment of the envelope opening mechanism 11 isthe envelope opening station described and disclosed in the '185 patent.Another embodiment of the envelope opening mechanism is depicted in FIG.6. The moving means positions the envelope in a manner in which lip 135is situated to allow insertion of media 75 into the outer pocket of thewaiting envelope. Envelope opening mechanism 11 is comprised of at leastone and preferably a plurality of elongated stems 165. At one end ofeach elongated stem 165 is a suction cup 170 through which a vacuum isselectively applied. Each suction cup communicates with a source ofvacuum through the attached elongated stem 165, which optionally ishollow, and an un-illustrated flexible hose, and is controlled by anun-illustrated controller. Near its other end each elongated stem 165 ismounted to a vertically erect post 185. The four posts 185A through 185Dshown in FIG. 6 are carried on a carriage means 245. The elongated stems165A through D serve to position the suction cups 170A through 170D overthe envelope. Optionally, elongated stems 165A through D can bepositioned or rotated horizontally at vertically erect posts 185Athrough 185D to position suction cups 170A through 170D over theenvelope. Elongated stems 165A through 165D are rotated vertically toposition suction cups 170A through 170D near the envelope so thatsuction cups 170A through 170D can open the outer pocket of the envelopeby application of vacuum there through. Elongated stems 165A through165D are optionally positioned or rotated vertically to further engagewith and open the outer pocket of the envelope. The envelope openingmechanism is timed and coordinated to be open to receive media 75 fromthe pusher assembly 10. The envelope opening mechanism 11 is controlledby an unillustrated controller.

[0049] Upon insertion of media 75 into the outer pocket of the envelope,the envelope is moved along movement path 180 by the moving means. Theenvelope is then sealed by a device and in a such manner as the envelopesealing structure described and disclosed in the '185 patent.

[0050] Optionally, the second media insertion station 6 furthercomprises one or more detecting means. One such error detection means,an error detection structure 175, generates at least one and preferablya plurality of optical error detection beams 230, which beams provide anindication whether or not media has been properly inserted into anenvelope. The error detection means detect media insertion and media andenvelope positioning errors near their physical placement and optimallythroughout the entire second media insertion station 6. The second mediainsertion station 6 optionally can include an unillustrated jamdetection structure as described and disclosed in the '185 patent. Thisunillustrated jam detection structure functions to detect media and/orenvelopes that have become jammed.

[0051] Additionally shown in FIG. 6 is an envelope sealing unit 225which may optionally comprise a part of the second media insertionstation 6 or alternatively comprise a part of the envelopesealing/receiving station 7. One embodiment of the envelope sealing unit225 is the envelope sealing mechanism described and disclosed in the'185 patent

[0052] The entire second media insertion station 6 is connected to anddriven by an unillustrated motor or other equivalent motivational means,in a manner well known in the art. One embodiment is the motor describedand disclosed in the '185 patent. Another embodiment is the drive motorsas described and disclosed in the '614 patent. The entire second mediainsertion station 6 is controlled by an unillustrated controller, in amanner well known in the art. One embodiment is the pusher fingerorientation control means as described and disclosed in the '185 patent.Another embodiment is the controller as described and disclosed in the'614 patent. The un-illustrated controller may optionally include atimer mechanism. The un-illustrated controller optionally is connectedto the un-illustrated motor, the un-illustrated timer, the errordetection structures, the un-illustrated printing mechanism, and theun-illustrated jam detection structure so as to provide a means forcoordinating and controlling the envelope feeding, first mediainsertion, second media insertion, envelope sealing and receivingfunctions.

[0053] In one embodiment of the invention the insertion method occurs insteps. In another embodiment of the invention, one or more of the stepsoccur automatically. In another embodiment of the invention all thesteps occur in a continuous stream. In a further embodiment the feedingsteps occur in an automatic, continuous stream and in a step-wisemovement. In again another embodiment of the invention, after theinsertion of the media inside the envelope there is a step to verifyproper insertion of the media inside the envelope. In a furtherembodiment, an address or like data is printed on the outside face ofthe envelope before the insertion of said media of said envelope.Similarly, in another embodiment, an address or like data is printed onthe media prior to being fed automatically and wherein said address orlike data corresponds to an address or like data printed on the outsideface of the envelope. In one optional embodiment, an unillustratedprinting mechanism prints an address or like data on the outer surfaceof the envelope after insertion of the media.

EXAMPLE

[0054] A dual pocket envelope is fed into the envelope insertion station4 and is moved along an envelope moving means 8. The moving means 8guides the envelope along movement path 180 to the first media insertionstation 5 wherein the inner pocket of the envelope can optionally beopened and inserted with media such as promotional material such asprinted paper. Whether or not media is inserted at the first mediainsertion station the moving means 8 then guides the envelope alongmovement path 180 to the second media insertion station. Prior to,concurrent with or thereafter, the envelope's arrival at the secondmedia insertion stations, the conveying arm 85 rotates through at least90 degrees so as to rotate the suction cup 80 into a positionsubstantially vertically aligned with the optical media disc 75 sittingon the media source 70. A vacuum is applied to the suction cup 80, theconveying arm 85 is then raised to remove the topmost optical media disc75 from the optical media supply 70, and then the conveying arm 85 isrotated at the rotatable hinge 195 through about 90 degrees of arc toposition the optical media disc 75 above the media rest 250 of thefeeding chute 200. The vacuum is released to cause suction cup 80 torelease the optical media disc 75 onto the media rest 250.

[0055] An air suspension system creates an air cushion through aplurality of vents 130 in the feeding chute 200, which facilitates themovement of the optical media disc 75 along path 210, further protectingthe optical media disc 75 from damage. The first and second guide wall110 and 115 respectively direct the optical media disc 75 along path210.

[0056] To begin the movement of the optical media disc, the feedingpiston 100 is activated by pneumatic pusher 205, which pushes theoptical media disc 75 from the media rest 250 along path 210. The pusherassembly 10 is timed and coordinated in a manner as to insert theoptical media disc into the outer pocket of the envelope positioned atthe lip 135 of the feeding chute 200. All the actions of the secondmedia insertion station are controlled by a controller.

[0057] The moving means positions the envelope at lip 135 prior toreceiving the optical media disc 75. The lip 135 contacts the upper edge19 of the right side panel 15 and the upper edge 34 of the left sidepanel 30. The lip 135 holds down the panels so that the envelope openingmechanism 11 can open only the outer pocket and not the inner pocket.The elongated stems 165A through 165D are rotated vertically to positionsuction cups 170A through 170D near the envelope and thereafter thesuction cups 170A through 170D engage and open the outer pocket of theenvelope by application of vacuum prior to and during the time periodduring which the optical media disc is inserted into the outer pocket ofthe envelope. Upon insertion of the optical media disc 75 into the outerpocket of the envelope, the suction cups 170A through 170D disengage andthe envelope is moved along the movement path 180 by the moving meanstowards the envelope sealing/receiving station 7.

[0058] Prior to reaching the envelope sealing/receiving station 7 theenvelope passes under the detection beams 230 of the error detectionstructure 175. If the beams are broken by any part of an improperlyinserted envelope, a controller steps in to stop the further operationof the equipment. If, on the other hand, the envelope is properlyinserted, the envelope passes under the error detection beams 230 andthe top panel 65 of the envelope is sealed by the sealing structure 225.

[0059] Next, after passing through the sealing structure 225, a printingmechanism prints an address on the outer surface of the envelope afterinsertion of the media. Finally, after printing the envelope is movedalong the movement path 180 to arrive at the end of the envelopesealing/receiving station 7 where the envelope is positioned for removalfrom the multiple station insertion device 3.

[0060] It is to be understood that while certain forms of the presentinvention have been illustrated and described herein, the presentinvention is not to be limited to the specific forms or arrangement ofparts described and shown.

What is claimed is as follows:
 1. A multiple pocket envelope made from aunitary blank and comprising; (a) a generally rectangular rear paneldefined on the top, left, right and bottom sides by fold lines said rearpanel having an inside and outside surface; (b) a set of opposed sidepanels each of said side panels being integrally joined to said rearpanel along one of said fold lines and being folded along into anoverlying relation with the inside surface of said rear panel, said sidepanels being of such a size and shape as to partially cover said rearpanel inside surface and to have their free side edges spaced a distancefrom each other so that a portion of the inside surface of the rearpanel is exposed there between, and said opposed side panels form aninner pocket having a mouth near the upper edge of said inside surfaceof rear panel; (c) a bottom panel, integrally joined to said rear panelalong the said bottom side fold line and being folded along said foldline into an overlying relation with said opposed side panels, saidbottom panel being of such size and shape as to partially cover saidopposed side panels, and said bottom panel forming an outer pockethaving a mouth near the upper edge of said rear panel inside surface;(d) a means for connecting said bottom panel to said side panels; (e) atop panel, integrally joined to said rear panel along said top side foldline and being folded along into an overlying relation with said bottompanel, said top panel being of such size and shape as to partially coversaid bottom panel, and said top panel enclosing the said inner and outerpockets and covering said mouths; and (f) a means for connecting saidtop panel to said bottom panel.
 2. The multiple pocket envelope as setforth in claim 1, further characterized by said side panels comprising asize and shape as to substantially cover said rear panel inside surfaceand to have their free side edges touching so that no portion of theinside surface of the rear panel is exposed there between.
 3. Themultiple pocket envelope as set forth in claim 1, further characterizedby said side panels comprising a size and shape as to totally cover saidrear panel inside surface and to have their free side edges touching sothat no portion of the inside surface of the rear panel is exposed therebetween.
 4. The multiple pocket envelope as set forth in claim 1,further characterized by said bottom panel comprising a size and shapeas to substantially cover said opposed side panels.
 5. The multiplepocket envelope as set forth in claim 1, further characterized by saidbottom panel comprising a size and shape as to totally cover saidopposed side panels.
 6. The multiple pocket envelope as set forth inclaim 1, further characterized by said top panel comprising a size andshape as to partially cover said bottom panel.
 7. The multiple pocketenvelope as set forth in claim 1, further characterized by said toppanel comprising a size and shape as to totally cover said bottom panel.8. The multiple pocket envelope as set forth in claim 1, furthercharacterized by a window in said bottom flap which reveals the contentsof the outer pocket.
 9. The multiple pocket envelope as set forth inclaim 1, further characterized by a window in said back flap whichreveals the contents of the inner pocket.
 10. The multiple pocketenvelope as set forth in claim 1, further characterized by either orboth side panels comprise a perforated line, wherein a portion or all ofsaid side panels can be detached at said perforated line.
 11. Themultiple pocket envelope as set forth in claim 10, wherein thedetachable portion of the side panel is a business reply card.
 12. Themultiple pocket envelope as set forth in claim 1, further characterizedby a semicircular recess along the edge of the bottom panel.
 13. Amethod for inserting media inside of an envelope, said method comprisingin sequence the operations of: (a) feeding an envelope, (b) sequentiallyfeeding media to be inserted inside said envelope, (c) inserting saidmedia inside the envelope.
 14. The method of claim 13, wherein one ormore of the steps occurs automatically.
 15. The method of claim 13,wherein either or both of the feeding steps occur in a stepwise motion.16. The method of claim 13, wherein all the steps occur in a continuousstream.
 17. The method of claim 13, wherein the feeding steps occur inan automatic, continuous stream and in a stepwise movement.
 18. Themethod of claim 13, wherein after the insertion of the media inside theenvelope there is the step of verifying the proper insertion of saidmedia inside of said envelope.
 19. The method of claim 13, wherein anaddress or like data is printed on the outside face of the envelopeafter the insertion of said media inside of said envelope.
 20. Themethod of claim 13, wherein an address or like data is printed on theoutside face of the envelope before the insertion of said media insideof said envelope.
 21. The method of claim 13, wherein an address or likedata is printed on the media prior to being fed automatically.
 22. Themethod of claim 13, wherein an address or like data is printed on themedia prior to being fed automatically, and wherein said address or likedata corresponds to an address or like data printed on the outside faceof the envelope.
 23. Equipment for inserting media inside envelopes,said equipment comprising; (a) a means for moving an envelope; (b) ameans for feeding an envelope onto said moving means; (c) a means forconveying said media; (d) a means for feeding said media towards saidmoving means; (e) a means for inserting said media inside the envelope;(f) a means for operatively connecting to and coordinating with andbetween said moving means, said envelope and media feeding means, saidconveying means, and said inserting means.
 24. The equipment of claim23, wherein said moving, envelope and media feeding, conveying andinserting means occurs in a stepwise fashion.
 25. The equipment of claim23, wherein said envelope moving means moves a continuous supply ofenvelopes stepwise.
 26. The equipment of claim 23, wherein said envelopefeeding means feeds a continuous supply of envelopes.
 27. The equipmentof claim 23, wherein said media feeding means feeds a continuous supplyof media.
 28. The equipment of claim 23, wherein a printing means printsan address or like data on the media prior to feeding.
 29. The equipmentof claim 23, wherein said means for operatively connecting to andcoordinating with and between said moving means, said envelope and mediafeeding means, said conveying means, and said inserting means is alsoconnected to and coordinated with and between said printing means.
 30. Amultiple media insertion device comprising (a) an envelope feedingstation; (b) a first media insertion station; (c) a second mediainsertion station; and (d) an envelope sealing/receiving station alloperatively connected therewith.
 31. An insertion device comprising: (a)an envelope feeding station; and (b) a media insertion stationoperatively connected therewith.
 32. A media insertion devicecomprising: (a) a media transfer assembly; (b) a feeding chute; (c) amoving means to position an envelope to receive media with respect tothe feeding chute; and (d) an envelope opening mechanism all operativelyconnected therewith.
 33. The media insertion device of claim 32 furthercomprising a pusher assembly.
 34. The media insertion device of claim32, wherein the media transfer assembly comprises: (a) a verticalsupport; (b) a conveying arm; (c) at least one suction cup affixed in afunctional manner to the conveying arm and through which vacuum isselectively applied; and (d) a hinge connected in a rotatable fashion toboth the vertical support and the conveying arm.
 34. The media insertiondevice of claim 32, wherein the feeding chute comprises: (a) a base; (b)a media rest area at one end of the base; and (c) a lip at the other endof the base.
 35. The media insertion device of claim 32 wherein thefeeding chute further comprises an air suspension system which providesan air cushion through a plurality of vents in the chute.
 36. The mediainsertion device of claim 32 wherein the feeding chute further comprisesa recessed groove to facilitate contact between a feeding piston and themedia.
 37. The media insertion device of claim 32 further comprising afeeding piston positioned, timed and coordinated in a manner so as topush media into an open envelope positioned at the lip of the feedingchute.
 38. The media insertion device of claim 32 wherein the envelopeopening mechanism further comprises: (a) at least one elongated stem;(b) a suction cup affixed functionally at the end of the elongated stem;(c) a vertical post to which the opposite end of the elongated stem ismountably fixed; and (d) a carriage means to which one or more of thevertical posts are affixed in a carrying manner so as to permitpositioning of the elongated stems.
 39. The media insertion device ofclaim 32 further comprising an envelope sealing means.
 40. The mediainsertion device of claim 32 further comprising one or more errordetecting means.